EP3017485A1 - Thermoelectric materials based on tetrahedrite structure for thermoelectric devices - Google Patents
Thermoelectric materials based on tetrahedrite structure for thermoelectric devicesInfo
- Publication number
- EP3017485A1 EP3017485A1 EP14820390.4A EP14820390A EP3017485A1 EP 3017485 A1 EP3017485 A1 EP 3017485A1 EP 14820390 A EP14820390 A EP 14820390A EP 3017485 A1 EP3017485 A1 EP 3017485A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- tetrahedrite
- thermoelectric
- powder
- thermoelectric device
- concentration
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
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Classifications
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10N—ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10N10/00—Thermoelectric devices comprising a junction of dissimilar materials, i.e. devices exhibiting Seebeck or Peltier effects
- H10N10/80—Constructional details
- H10N10/85—Thermoelectric active materials
- H10N10/851—Thermoelectric active materials comprising inorganic compositions
- H10N10/853—Thermoelectric active materials comprising inorganic compositions comprising arsenic, antimony or bismuth
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01G—COMPOUNDS CONTAINING METALS NOT COVERED BY SUBCLASSES C01D OR C01F
- C01G30/00—Compounds of antimony
- C01G30/002—Compounds containing, besides antimony, two or more other elements, with the exception of oxygen or hydrogen
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01G—COMPOUNDS CONTAINING METALS NOT COVERED BY SUBCLASSES C01D OR C01F
- C01G49/00—Compounds of iron
- C01G49/009—Compounds containing, besides iron, two or more other elements, with the exception of oxygen or hydrogen
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10N—ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10N10/00—Thermoelectric devices comprising a junction of dissimilar materials, i.e. devices exhibiting Seebeck or Peltier effects
- H10N10/01—Manufacture or treatment
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
- C01P2002/00—Crystal-structural characteristics
- C01P2002/70—Crystal-structural characteristics defined by measured X-ray, neutron or electron diffraction data
- C01P2002/72—Crystal-structural characteristics defined by measured X-ray, neutron or electron diffraction data by d-values or two theta-values, e.g. as X-ray diagram
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
- C01P2004/00—Particle morphology
- C01P2004/01—Particle morphology depicted by an image
- C01P2004/03—Particle morphology depicted by an image obtained by SEM
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
- C01P2006/00—Physical properties of inorganic compounds
- C01P2006/40—Electric properties
Definitions
- thermoelectric materials based on tetrahedrite structure for thermoelectric devices and, more particularly, to the manufacturing and uses for tetrahedrite like thermoelectric materials.
- thermoelectric materials may be used for direct conversion of heat to electricity and, thus, can substantially increase the efficiency of energetic processes.
- Current state of the art thermoelectric materials are comprised of elements which are in low abundance and often toxic.
- thermoelectric (TE) materials have been a focus topic in solid-state physics and materials science due to their potential application in waste energy harvesting or Peltier cooling.
- ZT the figure of merit
- the benchmark for a good thermoelectric material has been ZT of order unity, typified by Bi 2 Te 3 and its alloys which are used commercially in thermoelectric cooling modules.
- thermoelectric materials which are inexpensive, environmental-friendly, easy to synthesize, and comprised of earth-abundant elements.
- thermoelectric thermoelectric
- zT values can be raised to more than 1 .5 or even higher at high temperature, as has been shown for some filled skutterudites and bulk nano- structured chalcogenides.
- Biswas et al. reported that PbTe-SrTe doped with Na shows a maximum zT value of 2.2 at 923K due to a hierarchical structure that maximizes phonon scattering.
- many of these new materials use rare or toxic elements, impeding their application on a large scale.
- thermoelectric point of view More interesting from the thermoelectric point of view are crystalline solids which exhibit minimal thermal conductivity, due to strong intrinsic phonon scattering. Examples here include, in addition to the afore-mentioned skutterudites, complex cage structures such as clathrates. Recently, minimal thermal conductivity was discovered in crystalline rocksalt structure l-V-VI 2 compounds (e.g., AgSbTe 2 ), semiconductors typified by the lattice thermal conductivity of a glassy or amorphous system. These materials exhibit electronic properties characteristic of good crystals and thus have demonstrated good thermoelectric behavior.
- crystalline rocksalt structure l-V-VI 2 compounds e.g., AgSbTe 2
- semiconductors typified by the lattice thermal conductivity of a glassy or amorphous system.
- thermoelectric device has a pair of conductors and a p-type thermoelectric material disposed between the conductors.
- the thermoelectric material is at least partially formed of a hot pressed high energy milled tetrahedrite formed of tetrahedrite ore and pure elements to form a tetrahedrite powder of Cui 2 - x M x Sb Si 3 disposed between the conductors, where M is at least one of Zn and Fe.
- thermoelectric device a method of producing a thermoelectric device.
- the method included high energy milling tetrahedrite having natural tetrahedrite ore and pure elements to form a tetrahedrite powder of Cui2-xM x Sb Si 3 wherein M is selected from the group of Zn at a concentration 0 ⁇ x ⁇ 2.0, Fe at a concentration 0 ⁇ x ⁇ 1 .5, and combinations thereof.
- M is selected from the group of Zn at a concentration 0 ⁇ x ⁇ 2.0, Fe at a concentration 0 ⁇ x ⁇ 1 .5, and combinations thereof.
- the high energy milled tetrahedrite is hot pressed to form a pellet to a density greater than 95%.
- the pellet is then disposed between a pair of electrical conductors.
- thermoelectric is performed.
- the material is formed of a high energy milled tetrahedrite comprising natural tetrahedrite ore and powder elements to form a tetrahedrite powder of Cui 2 -xM x Sb - y ASySi 3 , wherein M is selected from the group of Zn at a concentration 0 ⁇ x ⁇ 2.0, Fe at a concentration 0 ⁇ x ⁇ 1 .5, and combinations thereof.
- thermoelectric device provides a pair of thermal conductor, and hot pressed high energy milled tetrahedrite comprising natural tetrahedrite and powder elements milled to form a tetrahedrite powder of Cui2-xM x Sb Si 3 disposed between the thermal conductors, where M is one of Zn and Fe.
- thermoelectric device provides a pair of conductors and a p-type thermoelectric material disposed between the conductors.
- the thermoelectric material is formed of hot pressed high energy milled tetrahedrite formed of tetrahedrite ore and pure elements to form a tetrahedrite powder of Cui2-xM x Sb Si 3 disposed between the conductors, where M is at least one of Zn and Fe.
- thermoelectric device a method of producing a thermoelectric device.
- the method included high energy milling tetrahedrite comprising natural tetrahedrite ore and pure elements to form a tetrahedrite powder of Cui 2 -xM x Sb Si 3 wherein M is selected from the group of Zn at a concentration 0 ⁇ x ⁇ 2.0, Fe at a concentration 0 ⁇ x ⁇ 1 .5, and combinations thereof.
- the tetrahedrite is hot pressed to form a pellet to a density greater than 95%.
- the pellet is disposed between a pair of electrical conductors.
- the chemical compositions described herein are synthesized from earth abundant materials and in some cases can be extracted in nearly ready- to-use form from the earth's crust. Furthermore, the compounds are comprised of elements of low atomic mass, such that the density of the compounds is significantly less than state of the art compounds. These compounds can be used in provide, lightweight, low-cost thermoelectric devices for large scale conversion of heat to electricity.
- Cui 2 Sb Si 3 the base composition of a large family of natural minerals called tetrahedrites, is structurally very closely related to the Cu 3 SbSe 3 phase; its unit cell can be considered as quadruplicate of the Cu 3 SbS 3 unit cell. It possesses a cubic sphalerite-like structure with six of the twelve Cu atoms occupying trigonal planar sites with the remaining Cu atoms distributed on tetrahedral sites. In terms of a crystal-chemical formula, four of the six tetrahedral sites are thought to be occupied by monovalent Cu, while the other two are occupied by Cu 2+ ions; the trigonal planar sites are occupied solely by monovalent Cu.
- Magnetic measurements supporting the present invention reveal that antiferromagnetic interactions occur between the Cu 2+ ions and induce a magnetic ordering transition below 83 K.
- the Sb atoms also occupy a tetrahedral site but are bonded to only three sulfur atoms, leading to a void in the structure and a lone pair of electrons, just as Cu 3 SbSe 3 .
- a powder processing procedure is disclosed using natural mineral tetrahedrite ore, the most widespread sulfosalt on earth to provide a low cost, high throughput mechanism of producing thermoelectric materials with high conversion efficiency.
- the current teachings are superior to the prior art because they describe compounds that 1 ) are made from earth-abundant elements and are themselves common and widespread minerals in the earth crust; 2) consist of elements of light atomic mass, leading to low density and ultimately lower weight devices; 3) require no special processing beyond melting, annealing, and powder processing; 4) exhibit large thermoelectric figure of merit can be maintained over a wide range of composition, simplifying the synthesis procedure; and 5) are of composition that span the range of compositions of the large mineral families of tetrahedrite and tennantite, indicating that these minerals may be used directly as source materials for high efficiency thermoelectrics, leading to considerable cost savings.
- Figure 1 represents a tetrahedrite structure according to the present teachings
- Figure 2a represents an electrical resistivity of synthetic tetrahedrite of composition Cui 2 -xZn x Sb Si 3 above room temperature;
- Figure 2b represents the Seebeck coefficient of tetrahedrite of composition Cui 2 -xZn x Sb Si 3 ; sample designation as in Figure 2a;
- Figure 3a total lattice thermal conductivities of Cui 2 -xZn x Sb Si 3 ;
- Figure 3b represents lattice thermal conductivities of Cui 2 - x Zn x Sb 4 Si 3 ;
- Figure 4a represents the dimensionless thermoelectric figure of merit ZT as a function of temperature for tetrahedrite Cui 2 - x Zn x Sb Si 3 ;
- Figures 5a and 5b represent X-ray diffraction patterns for a) Cui 2 . x Zn 2 . x Sb Si 3 and b) Cui 2 - x Fe 2 . x Sb Si 3 samples;
- Figures 6a and 6b represent a) thermal diffusivity and b) specific heat capacity for synthetic tetrahedrite specimens
- Figure 6c represents conductivity vs. T "1 for the synthetic species
- Figure 7 represents low temperature electrical conductivity versus inverse temperature for Cui 2 - x Zn 2 . x Sb Si 3;
- Figure 8 represents a system for forming the materials according to the present teachings
- Figure 9 represents a thermoelectric device according to the present teachings.
- Figures 10 and 1 1 represent x-ray diffraction patterns for the disclosed materials under varying processing conditions;
- Figures 12-17 represent various material properties for the materials disclosed herein;
- Figure 18 represents an x-ray diffraction pattern of various disclosed materials according to the present teachings.
- Figures 19-21 represent SEM images of various materials according to the present teachings.
- thermoelectric materials can convert waste heat into electricity, potentially improving the efficiency of energy usage in both industry and everyday life.
- known good thermoelectric materials often are comprised of elements that are in low abundance and/or toxic, and frequently require careful doping and complex synthesis procedures.
- high thermoelectric figure of merit in compounds of the form Cui 2 -xTM x Sb Si 3 , where TM is a transition metal, such as Zn or Fe.
- TM is a transition metal, such as Zn or Fe.
- the dimensionless figure of merit reaches 0.9 around 673K, comparable to that of other state of art p- type thermoelectric materials in the same temperature range.
- the figure of merit remains high for a wide range of values of x.
- the subject compositions are among those that form the class of natural minerals known as tetrahedrites.
- Thermoelectrics comprised of earth-abundant elements will pave the way to many new, low cost thermoelectric energy generation opportunities.
- FIG. 3a displays thermal conductivity derived from thermal diffusivity measurements above room temperature.
- the thermal conductivity is below 1 .5 W m "1 K "1 over the entire temperature range.
- the thermal conductivity falls monotonically with increasing Zn substitution. This reflects the combined effects of a reduced electronic component of thermal conductivity and a decreasing lattice contribution. If applied, the Wiedemann-Franz law estimates the electronic contribution, extracted is the lattice thermal conductivity of the samples.
- the Zn-substituted samples all have lattice thermal conductivity in the range of 0.2 - 0.5 W m "1 K "1 , and in fact even the pure tetrahedrite sample falls into this range at the highest temperature.
- This value of lattice thermal conductivity is close to the "minimal" thermal conductivity for a phonon mean free path equal to the interatomic spacing.
- thermoelectric figure of merit ( Figure 4a).
- the high ZT values are maintained for relatively large Zn substitutions due to the compensating effect from the reduction in thermal conductivity.
- thermoelectric properties [0049] Synthesized single phase and high density Zn and Fe substituted Cui 2 Sb4Si3 provides preferred thermoelectric properties.
- the intrinsic low lattice thermal conductivities give birth to high ZT values comparable to state of art thermoelectric materials in the range of 600 - 700 K.
- the maximum ZT values are 0.91 and 0.83 for Zn and Fe substitutions, respectively.
- a thermoelectric figure of merit above 0.6 can be maintained over a large range of substitution level, and is related to the occupation fraction of Brillouin-zone. Unlike traditional thermoelectric materials that require careful control over doping level and synthesis conditions, the mineral tetrahedrite can likely be used with little processing effort as an earth- abundant resource for high performance thermoelectricity.
- the material can be formed by ball milling and more particularly by high energy ball milling.
- Ball milling (and in particular High - energy ball milling) represents a way of inducing phase transformations in starting powders whose particles have all the same chemical composition. For example, amorphization or polymorphic transformations of compounds, disordering of ordered alloys can be produced. Although the principles of these operations are same for all the techniques, this alloying process can be carried out using different apparatus, namely, attritor, planetary mill or a horizontal ball mill.
- the powders are cold welded and fractured during mechanical alloying, it is critical to establish a balance between the two processes in order to alloy successfully.
- the ball mill system has a turn-table and two or rotatable four bowls.
- the turn-table rotates in one direction while the bowls rotate in the opposite direction.
- the centrifugal forces created by the rotation of the bowl around its own axis together with the rotation of the turn disc, are applied to the powder mixture and milling balls in the bowl.
- the powder mixture is fractured and cold welded under high energy impact.
- the centrifugal forces are alternately synchronized.
- friction resulted from the hardened milling balls and the powder mixture being ground alternately rolling on the inner wall of the bowl and striking the opposite wall.
- the impact energy of the milling balls in the normal direction attains a value of up to 40 times higher than that due to gravitational acceleration.
- the planetary ball mill can be used for high-speed milling.
- the powder particles are subjected to high energetic impact.
- the mechanical alloying process can be divided into several stages: mixing stage, intermediate stage, final stage, and completion stage.
- phase transitions under milling are complex processes which depend on many factors. For instance phase transitions can depend on physical and chemical parameters such as the precise dynamical conditions, temperature, nature of the grinding atmosphere, chemical composition of the powder mixtures, chemical nature of the grinding tools, etc. It has been found that by starting with mineral tetrahedrite, materials added to the high energy mill will form into the same tetrahedrite structure. As such, by using a "starter" crystal structure from a natural or laboratory produced material, large volumes of specific crystals can be formed using this method.
- high energy ball milling can be used to form a powdered material having a crystal structure and a first stoichiometric ratio.
- a first portion of a first material having the crystal structure and a second stoichiometric ratio is placed in a high energy ball mill with a second portion of a second material formed of a mixture of powder materials having a third stoichiometric ratio.
- the first and second portions of the materials hard high energy ball milled together together to form a third portion of the powdered material having the crystal structure having the first stoichiometric ratio.
- stoichiometric ratios can be varied.
- the second stoichiometric ratio can be the first stoichiometric ratio, or the third stoichiometric ratio can different than the second stoichiometric ratio.
- the first portion can contain a naturally occurring ore. To maintain the crystal structure and reduce the number of secondary crystal structures, the first portion can be more than 50% by weight of the third portion.
- Low temperature resistivity shows that the resistivity decreases strongly with increasing temperature and is consistent with a hopping-type mechanism.
- the magnitude of the resistivity is in the range typical of good thermoelectric materials.
- Figure 2b shows the Seebeck coefficient of tetrahedrite of composition Cui 2 -xZn x Sb Si 3 ; sample designation as in Figure 2a. Seebeck coefficient rise strongly with temperature and Zn content, reaching values in excess of 200 uV K "1 .
- Figure 3a represents the total thermal conductivities of Cui 2 - x Zn x Sb Si3.
- Figure 3b represents lattice thermal conductivities of Cui 2 - x Zn x Sb Si 3 .
- the magnitude of the conductivity is comparable to or even smaller than typical thermoelectric materials like lead telluride or skutterudite.
- Zn- containing samples approach minimal thermal conductivity values over most of the temperature range, as does pure tetrahedrite at the highest measurement temperatures.
- Figure 4a represents Dimensionless thermoelectric figure of merit ZT as a function of temperature for tetrahedrite Cui 2 -xZn x Sb Si 3 .
- the electronic thermal conductivity plays a special role in controlling their thermoelectric properties. With increasing Zn content, the resistivity rises, causing the power factor to decrease, but this is more than made up for by a decrease in electronic thermal conductivity.
- Cui 2 (Fe,Zn) 2 Sb Si3 samples were synthesized by direct reaction of the starting elements- Cu (99.99 %, Alfa- Aesar), Sb (99.9999 %, Alfa-Aesar), and S, Zn ,Fe (99.999%, Alfa-Aesar).
- the elements were weighted out in stoichiometric proportions using a high-precision Mettler balance; typical charges were on the order of 5 grams total, with individual element masses weighted out with an accuracy of 0.0005 g (0.5 mg).
- the stoichiometric proportions of the elements were placed into quartz ampoules of inside diameter 10 mm and wall thickness 0.5 mm.
- the ampoules were evacuated of air using a turbo molecular pump; typical final pressures were ⁇ 10 "5 Torr.
- the ampoules were sealed under dynamic vacuum using an oxygen/methane torch and provided with a small quartz hook on the top. A wire was attached to this hook and the ampoules were suspended in a vertical Thermolyne tube furnace at room temperature. The furnace was heated at 0.3 Q C min "1 to 650 Q C and held at that temperature for 12 hours. Subsequently, the furnace was cooled to room temperature at the rate of 0.4 Q C min "1 .
- the reacted material was placed into a stainless vial and ball milled for five minutes in a SPEX sample preparation machine. These ball-milled powders were then cold pressed into a pellet and re-ampouled under vacuum for annealing for two weeks at 450 Q C. It is envisioned the material can be annealed for less time or at a different temperature. The final product after annealing was ball milled for 30 minutes into fine powders and hot-pressed under argon atmosphere at 80 MPa pressure and 430 Q C for 30 minutes.
- hot poured samples can have a theoretical density of > 95 %. Synthesized two batches each of Cui2-xZn 2 -xSb Si 3 and Cui 2 - x Fe 2 . x Sb Si3 samples. The high temperature thermoelectric property results presented herein were all gathered from the same pellet for each of the compositions. For some of the low temperature data, different pellets of the same nominal composition were used.
- Figures 5a and 5b represent X-ray diffraction patterns for a) Cui 2 - x Zn 2 - x Sb Si3 and b) Cui 2 - x Fe 2 - x Sb Si 3 samples.
- X-ray diffraction analysis of all of the synthesized specimens was performed by using a Rigaku Miniflex II bench-top X-ray diffractometer (Cu K Q radiation), and the results analyzed using a Jade software package. For each sample a small amount of hot-pressed material was powdered, spread on a microscope slide, and placed in the x-ray beam.
- Figures 5a) and 5b) show results of x-rays scans on representative Cui 2 - x Zn 2 - x Sb Si 3 and Cui 2 - x Fe 2 -xSb Si3 samples, respectively. All peaks index to the tetrahedrite phase. Also shown is an x-ray scan gathered from a natural mineral specimen; again the peaks index to the tetrahedrite phase. There is a small shift in the location of the peaks in the natural mineral relative to the synthetic specimens, most likely because the natural mineral contains a mixture of Sb and As on the semi metal site.
- the material according to the present teachings can contain Cui 2 .
- Density measurements were performed using the Archimedes method with water as the suspending fluid. Low temperature resistivity was measured in a cryostat using four-probe technique on samples from a different batch than that used for high temperature measurements, but of the same nominal composition. The resulting data is shown in Figure 6c.
- Figure 7 shows a plot of conductivity versus T "1 , as one might expect for carrier activation, for the Zn-containing samples. The results do not fill well to this model. Rather the data are better-described by a hopping type model.
- the Fe-containing samples can be described similarly. Low temperature Seebeck coefficients were measured on a series of Zn-containing samples in a flow cryostat using a steady state method. One end of a prism-shaped sample was attached to the cold head of the cryostat, while a small metal film heater/resistor embedded in copper was affixed to the other end. Two copper -constantan thermocouples were attached along the length of the sample to detect the temperature difference dT.
- thermocouples were used to measure the Seebeck voltage. Both the high and low temperature Seebeck measurements by also measuring a bismuth telluride Seebeck standard sample (NIST SRM-xxxx), and found differences between measurements and the calibration values of no more than 5% over the range 80 - 573 K.
- Low temperature Seebeck measurements for the Zn- containing samples are shown in Figure 6c. Values near room temperature differ slightly from those shown in Figure 2c), because the samples measured at low temperature were from a different batch of the same nominal composition. Slight differences in absolute value from sample to sample are expected, because the properties depend on the actual content of Zn.
- Figure 7 represents low temperature electrical conductivity versus inverse temperature for Cui2-xZn 2 -xSb Si 3 .
- thermoelectric figure of merit remains in the range of 0.6-0.9 at 673 K, similar to or even exceeding that of the best state of the art thermoelectric materials in this temperature range.
- Optionally Tellium can be substituted as a percentage of the S, or Cd can be substituted for Cu at certain fractions. This means that these natural minerals may be used directly or with small compositional modification as source materials for thermoelectric devices once processed into a pelletized or film structure.
- thermoelectric devices using this material can be used for converting heat to electricity or electricity to cause a heat gradient.
- the device 98 has a first electrode 100 and a thermoelectric material disposed between the electrodes. It is envisioned that any of the materials disclosed herein can be used as a thermoelectric device. As such, they may be used, for example, to convert waste heat from an automobile engine or other vehicle to useful electrical power. Other potential industry targets include waste heat conversion in power generation (coal - and natural gas-burning power plants), steel production, and in residential/commercial boilers and water heaters. Further, thermoelectric materials are being developed for direct conversion of solar thermal energy to electricity, thereby acting to complement traditional solar cell technology.
- a thermoelectric device can have a pair of electrical and thermal conductors and a layer of tetrahedrite as a p-type or n-type material disposed between the pair of conductors.
- the layer of tetrahedrite has Cui2-xM x Sb Si 3 , M is selected from the group of Zn, Fe, and combinations thereof.
- M is selected from the group of Zn, Fe, and combinations thereof.
- n-type or p- type materials As shown in Figures 10 and 1 1 , this other material could be a material other than a tetrahedrite.
- M being selected from the group consisting of Zn at a concentration 0 ⁇ x ⁇ 2.0 or Fe at a concentration between 0 ⁇ x ⁇ 1 .5, or combinations thereof.
- the Cui 2 Sb Si 3 samples can be synthesized by direct solid state reaction of the starting elements- Cu (99.99 %, Alfa-Aesar), Sb (99.9999 %, Alfa- Aesar), and S, Zn ,Fe (99.999%, Alfa-Aesar). These raw materials were loaded in stoichiometric ratios into quartz ampoules that were evacuated to ⁇ 10 "5 Torr. The loaded ampoules were then placed into a vertical furnace and heated at 0.3 Q C min "1 to 650 Q C and held at that temperature for 12 hours. Subsequently, they were slowly cooled to room temperature at the rate of 0.4 Q C min "1 .
- the resulting reacted material was placed into a stainless vial and ball milled for five minutes in a SPEX sample preparation machine. These ball-milled powders were then cold pressed into a pellet and re-ampouled under vacuum for annealing for two weeks at 450 Q C. The final product after annealing was ball milled for 30 minutes into fine powders and hot-pressed under argon atmosphere at 80 MPa pressure and 430 Q C for 30 minutes. All the hot pressed samples were greater than 98% theoretical density, as measured using the Archimedes method.
- phase such as Cu 3 SbS that have high thermocoefficients can be formed.
- the annealing step is useful in reducing the amounts of secondary and tertiary phases. Grinding and hot pressing increases the density thus improving electrical conductivity an improving handling properties.
- XRD analysis was performed by using a Rigaku Miniflex II bench- top X-ray diffractometer (Cu K Q radiation), and the results analyzed using a Jade software package. High temperature (373K-673K) Seebeck coefficient and electrical resistivity were measured in an Ulvac ZEM-3 system under argon.
- Low temperature Seebeck coefficient and resistivity were measured in a cryostat using four-probe techniques on samples from a different batch than that used for high temperature measurements, but of the same nominal composition.
- the thermal diffusivity (D) and heat capacity (C p ) from 373K to 673K were measured using the laser flash method (Netzsch, LFA 457) and differential scanning calorimetry (Netzsch, DSC200F3) respectively.
- the data were also confirmed independently in a second laboratory using an Anter Flashline 5000 thermal diffusivity apparatus and a calorimeter.
- the samples used for these measurements were from adjacent sections of the same pellets as those used for high temperature resistivity and Seebeck coefficient.
- the thermoelectric device can have a pair of conductors (thermal and electrical), and a layer of tetrahedrite disposed between the pair of conductors.
- the layer of tetrahedrite has Cui2-xM x Sb - y ASySi 3 where M is selected from the group of Zn at a concentration 0 ⁇ x ⁇ 2.0, Fe at a concentration 0 ⁇ x ⁇ 1 .5, and combinations thereof.
- the device can use a sintered tetrahedrite comprising Cui2-xM x Sb - y ASySi 3 wherein M is selected from the group of Zn at a concentration 0 ⁇ x ⁇ 2.0, Fe at a concentration 0 ⁇ x ⁇ 1 .5, and combinations thereof.
- thermoelectric device material comprising Cui 2 - x M x Sb Si 3 wherein M is selected from the group of Zn at a concentration 0 ⁇ x ⁇ 2.0, Fe at a concentration 0 ⁇ x ⁇ 1 .5, and combinations thereof is sintered to form a tetrahedrite microstructure.
- the sintered material is ground using a mill, and hot pressed, to a density of greater than 95% to form a pellet.
- the pellet is placed between a pair of electrical conductors.
- Tetrahedrite-structure compounds of general composition Cui 2 - x Zn x Sb4Si3, are an earth-abundant alternative to PbTe for thermoelectric power generation applications in the intermediate high temperature range (300 - 400 °C). Tetrahedrites can be synthesized in the laboratory using a multi-step process involving long annealing times. However, this compound also exists in natural mineral form and, in fact, is one of the most abundant copper-bearing minerals in the world. By simply mixing natural mineral tetrahedrite with pure elements through high-energy ball milling without any further heat treatment, material with figure of merit near unity at 723K can be obtained.
- thermoelectric materials with intrinsically low lattice thermal conductivity caused by large lattice anharmonicity.
- One example is the newly reported copper- antimony/arsenic-sulfur ternary family of compounds known as tetrahedrite/tennantite, which occurs also as a natural mineral and is in fact the most widespread sulfosalt on Earth.
- This class of compounds of general composition Cui2-x(Zn,Fe) x (Sb,As) Si 3 with 0 ⁇ x ⁇ 2, has a strongly anharmonic phonon spectrum, which is thought to arise from the existence of a lone pair of electrons surrounding the Sb/As atoms.
- thermoelectric devices using natural minerals themselves may serve directly as source thermoelectric materials if their compositions can be adjusted to fall into the optimum range for thermoelectricity, namely a Zn (Fe) concentration of 1 .0-1 .5, corresponding to a Cu concentration of 10.5-1 1 .0.
- minerals can be chemically modified so as to place the material into the optimum range for thermoelectricity, namely a Zn (Fe) concentration of 1 .0-1 .5, corresponding to a Cu concentration of 10.5-1 1 .0.
- thermoelectric material As described below, a rapid method of synthesizing tetrahedrite thermoelectric material by high energy ball milling of natural mineral powder or ore mixed with small amounts of elemental Cu, Sb, and S powder, followed by consolidation using hot pressing is presented. A preferable feature of this process is that it requires no additional heat treatment. The presence of the natural mineral tetrahedrite acts as a "seed matrix" that accepts the additional elements into its structure, thus modifying the composition to yield high zT of approximately 0.9 at 723K. This value compares very favorably with other p type thermoelectric materials in this temperature region.
- Figure 8 represents a system for forming the materials according to the present teachings. This phases form readily when Cu, Sb, and S are ball milled together alone without the natural mineral present. When the ball milling time is increased to 3 hours, this impurity phase of Cu 3 SbS becomes minute; after six hours of milling, the sample is almost exclusively tetrahedrite structure with only a trace amount of Cu, which is observed in all of the ball milled samples.
- Figures 10 and 1 1 represent an XRD of the materials showing that that milling the elemental powders for three to six hours is sufficient to form single-phase tetrahedrite solid solution in the presence of the natural mineral.
- pure elements by in the ratio of 12:4:13 were ball milled without the presence of the natural mineral. After 6 hours of ball milling, the final product has at least 50% Cu 3 SbS .
- the amount of natural crystal or ore which is used to seed the material in the ball mill can vary from >0 to about 75%, and particularly between 10% and 60%, and most particularly between more than 40% and less than about 50%.
- This seed crystal could be formed of stoichiometrically pure materials which have been sintered as described above.
- the pure materials in a proper stoichiometric ratio can be slowly added to the high energy ball mill to assist in the facilitation of the incorporation of the material to grow the desired crystal structure in the form of a powder.
- Figures 12-15 show varying material properties related to the material. As shown, variation of X from 0 to 1 .5 result in varying material properties such a s Seebeck coefficient, resistivity, Power factor, Laterla thermal conductivity ZT.
- Figure 16 shows ZT vs Brillouin zone occupation fraction. Shown is the similarities and differences in occupation fraction between Zn and FE. shows the temperature dependence of the thermoelectric properties of the mixture of natural mineral and pure elements after ball milling and consolidation. Samples with 25 wt% and 50 wt% pure elements added to the natural mineral for different ball milling time were investigated.
- the amount of pure element addition also has significant effect on the Seebeck coefficient.
- the Seebeck coefficients are all between 250 and 300 while for 50 wt% element addition samples, the Seebeck coefficients are reduced to 150-200 due to an increase in carrier concentration.
- the power factor results shown in Figure 1 1 c indicate that the 25% pure element addition samples have a maximum value of power factor of 3
- the degradation of electrical conductivity is offset by enhancement of the Seebeck coefficient, and the power factor remains at a high value of 5.8
- thermoelectric materials with zT of 0.9 were synthesized by using natural mineral tetrahedrite and a high-energy ball milling method. Nearly single-phase tetrahedrites with compositions optimized for thermoelectric performance were obtained after ball milling the natural mineral tetrahedrite and pure elements without additional heat treatment. The high zT value results from the intrinsic low thermal conductivity of the tetrahedrite crystal structure and the small grain size of the pressed pellets.
- thermoelectric materials with zT values of unity at 723 K, comparable to other p-type thermoelectric materials in this temperature region. While these minerals potentially contain toxic arsenic, the content of this element in actual minerals is very low (at maximum 13 atomic percent in pure tennantite, but more typically less than 5 atomic percent in most mineral rendering them far less toxic than PbTe-based compounds which contain as much as 50 atomic percent Pb.
- NMI Natural Mineral 1
- NM2 Natural Mineral 2
- SEM Scanning Electron Microscope
- sample SYN pure synthetic Cui 2 Sb 4 Si3
- the SYN sample was then pulverized with a mortar and pestle and the powder were mixed with natural mineral powders in a stainless balling milling vial with stainless steel balls in mass ratios of 1 :3,1 :1 and 3:1 .
- the vial was sealed in an argon-filled glove box and the powder mixture was milled for 30 min using a SPEX Sample Prep 8000 Series Mixer/Mill.
- the fine powder after the ball milling was loaded into a high-density graphite die with diameter of 10 mm for hot pressing under argon atmosphere.
- phase purity of the hot-pressed pellets was checked by performing X-ray diffraction analysis (using a Rigaku Miniflex II bench-top X-ray diffractometer) on powders obtained from small pieces of the pellets.
- the diffraction patterns were analyzed using a Jade software package.
- the micromorphology and homogeneity of samples were characterized using SEM. Seebeck coefficient and electrical resistivity was measured in an Ulvac ZEM-3 system under helium atmosphere from room temperature to 723 K.
- Seebeck coefficient and electrical resistivity was measured in an Ulvac ZEM-3 system under helium atmosphere from room temperature to 723 K.
- data were collected on both heating and cooling cycles; the difference of power factor between heating and cooling at the same temperature point was within 10%.
- no evidence of evaporation or degradation of any of the samples after heating to 723 K was observed.
- the thermal diffusivity (£>) was measured using the laser flash method (Netzsch, LFA 457) with all samples coated with carbon. For all samples, thermal diffusivity measurements were performed twice on two different disks with the same composition but different thickness in order to avoid the influence of laser stabilization time.
- Figure 17 depict Electronic properties of tetrahedrite.
- the magnitude of the resistivity is in the range typical of good thermoelectric materials.
- Open circles represent a pellet synthesized from natural tetrahedrite of nominal composition Cu A Fe, 5 As 3 6 Sb 0 4 Si 3 , while the open triangles are for a pellet synthesized using a combination of this natural material and synthetic Cui 2 Sb Si 3 .
- b Electronic band structure and density-of states (DOS) of Cui 2 Sb Si 3 . Fermi level is marked by a dashed line.
- DOS density-of states
- Fermi level is marked by a dashed line.
- Decomposition ofthe total DOS into contributions from Cu, Sb, and S shows the predominantly Cu 3d and S 3p character of valence bands, c). Seebeck coefficient oftetrahedrite of com position Cui2_xZn x Sb Si 3 ; sample designation as in a).
- Seebeck coefficient rises strongly with temperature and Zn content, reaching values in excess of200 (.iV K "1 .
- the Seebeck coefficient of the pellet synthesized using natural mineral tetrahedrite can be controlled by dilution with synthetic source material.
- FIG 19 Scanning electron microscope (SEM) images for a hot-pressed (0.50 NM2 :0.50 SYN) sample.
- Top left SEM image of a fractured surface, indicating grain size in the range of 100-500 nm.
- the remaining images display maps of the atomic distribution, as determined by Electron Dispersive X-ray (EDX) analysis, of S, Cu, As, Sb, and Zn, respectively and indicated a uniform distribution of these elements in the sample .
- Figure 20 represents SEM images of the (1 .0 NM2 :1 .0 SYN) mixture after hot pressing.
- the SEM image on the fracture surface reveals grain size of in the range of 100-500 nm.
- the small grain size was induced during the balling milling process, and is largely maintained throughout the hot pressing procedure, which is carried out at relatively low temperature. Although the tetrahedrites have very low intrinsic thermal conductivity, additional phonon scattering from grain boundaries may also contribute to the low thermal conductivity. EDS analysis performed on the same area of the SEM image shows that all the major elements in the mixture are homogeneously distributed throughout the sample, which also provides further evidence for the formation of a perfect solid solution between the natural mineral and pure SYN.
- the samples had total mass around 2 g of elemental Cu (powder, 10 micron, 99.9%), Sb (shot, 99.999%), S (pieces, 99.999%) from Alfa Aesar were weighed by stoichiometry of Cui2Sb4Si3 and loaded into a tungsten carbide vial with tungsten carbide balls. Subsequently, the raw natural mineral[ref] with composition of Cu9jZni.
- Milling times of one, three, and six hours were performed to investigate the effect of milling time on the phase formation and grain size.
- the product powders were hot pressed in high density graphite dies with 10mm diameter at 723K and 80MPa pressure for 30 minutes, in an argon- filled glove box, followed by free cooling to ambient temperature in 3 hours.
- the final products were then cut using a diamond saw into two samples of different geometry: a) a bar of dimension 3cmx3cmx8cm, for electronic transport measurements, and b) a disk of diameter 10mm diameter disk and thickness of 1 .5 mm, for thermal diffusivity measurement.
- Figure 21 depicts Scanning electron microscope (SEM) images for a sample with 50%wt pure element addition: (a) the specimen with 1 hour ball milling; (b) the specimen with 3 hour ball milling; (c) the specimen with 6 hour ball milling.
- the average grain size for the three cases is 330, 180, and 150 nm, respectively.
- Shown are Scanning Electron Microscopy (SEM) images of fracture surfaces of a disk hot pressed using powder consisting of 50% elements and 50 % natural mineral as a function of ball milling time are shown in Figure 2. As the ball milling time is increased from one to three hours, the average grain size is reduced from 330nm to 180 nm; milling for six hours, however, reduces the grain size to only 150 nm.
- Figure 22 represents Thermal conductivity of tetrahedrite specimens, a) total and b) lattice thermal conductivities ofCui2_xZn x Sb Si 3 .
- the magnitude ofthe conductivity is comparable to or even smaller than typical thermoelectric materials like lead telluride or skutterudite.
- Zn-containing samples approach minimal thermal conductivity values over most of the temperature range, as does pure Cui 2 Sb Si 3 at the highest measurement temperatures.
- Figure 23 Electrical and thermal transport properties of tetrahedrite-based samples, made by hot-pressing mixtures of natural mineral tetrahedrite (NM1 or NM2) and synthetic tetrahedrite (designated SYN).
- Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.
- first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.
- Spatially relative terms such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures.
- Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features.
- the example term “below” can encompass both an orientation of above and below.
- the device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
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WO2009135013A2 (en) * | 2008-04-30 | 2009-11-05 | Massachusetts Institute Of Technology (Mit) | Thermoelectric skutterudite compositions and methods for producing the same |
US8524362B2 (en) | 2009-08-14 | 2013-09-03 | Rensselaer Polytechnic Institute | Doped pnictogen chalcogenide nanoplates, methods of making, and assemblies and films thereof |
CN101993247A (en) | 2009-08-28 | 2011-03-30 | 中国科学院物理研究所 | Perovskite structure-based single-phase iron-based superconductive material and preparation method thereof |
JP5395577B2 (en) | 2009-09-10 | 2014-01-22 | 株式会社東芝 | Thermoelectric conversion module |
CN104396021B (en) | 2012-01-31 | 2016-10-12 | 陶氏环球技术有限责任公司 | Manufacture method including the photovoltaic device of the pnictide semiconductor film improved |
KR20150044883A (en) | 2012-07-06 | 2015-04-27 | 보드 오브 트러스티즈 오브 미시건 스테이트 유니버시티 | Thermoelectric materials based on tetrahedrite structure for thermoelectric devices |
WO2014168963A1 (en) | 2013-04-08 | 2014-10-16 | State Of Oregon Acting By And Through The State Board Of Higher Education On Behalf Of Oregon State | Semiconductor materials |
US20180233646A1 (en) | 2015-08-06 | 2018-08-16 | Board Of Trustees Of Michigan State University | Thermoelectric materials based on tetrahedrite structure for thermoelectric devices |
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- 2014-07-03 EP EP14820390.4A patent/EP3017485B1/en active Active
- 2014-07-03 US US14/901,206 patent/US10622534B2/en active Active
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JP2016529699A (en) | 2016-09-23 |
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WO2015003157A1 (en) | 2015-01-08 |
US10622534B2 (en) | 2020-04-14 |
US20160141481A1 (en) | 2016-05-19 |
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